Cutting tool with replaceable cutting inserts

ABSTRACT

The present invention relates to a cutting tool and a cutting insert. The tool includes a toolholder and at least one insert adapted for mounting relative to the toolholder. The at least one insert includes at least one chip removal channel.

DESCRIPTION

The present invention relates to cutting tools and, more particularly, to cutting tools having replaceable cutting inserts.

The useful life and/or usefulness of a cutting tool can often be improved by providing it with replaceable cutting inserts on which cutting edges for cutting a workpiece are provided. Instead of, for example, disposing of the cutting tool when a cutting edge breaks or becomes worn, the cutting insert can be replaced and the cutting tool can be used again. Also, the cutting inserts can be made of material that is better adapted to perform a cutting operation on a workpiece than the material from which the remainder of the cutting tool, often called a toolholder, is formed.

Such cutting tools with replaceable inserts are used in a variety of applications. For example, it is known to dress the opposing tips of welding electrodes using cutting tools with replaceable cutting inserts such as is disclosed in, for example, U.S. Pat. No. 5,401,127, which is incorporated by reference. This patent describes a cutting tool that uses a Y-shaped and/or triangular cutting inserts arranged around a central opening through which the axis of rotation of the cutting tool passes to simultaneously dress a top and a bottom electrode extending into the central opening from opposite ends of the central opening. Though the inserts in the cutting tool are replaceable, they are usable in only a single orientation relative to the cutting tool and the costs of operating the tool may be high.

Certain replaceable cutting inserts are indexable, i.e., can be oriented in plural different ways on the cutting tool to expose one or more of plural useable cutting edges to a workpiece. Many cutting tools, however, do not readily lend themselves to being provided with an indexable cutting insert. The cutting inserts used in U.S. Pat. No. 5,401,127, for example, cannot be indexed.

A common technique of securing an indexable cutting insert to a toolholder is to use a screw that passes through a hole in a central region of the cutting insert and has threads that engage with threads in a hole formed in a pocket for the insert in the toolholder. The insert is typically indexed to one of two or more positions by being rotated around the screw. In some toolholders, however, it is difficult to provide a suitable threaded hole in the pocket of the toolholder. For example, it may be necessary to form the pocket on a relatively thin or fragile portion of the toolholder, and providing the threaded hole risks damage to the toolholder or insufficient support for the insert.

In accordance with an aspect of the invention, a cutting tool includes a toolholder and at least one insert adapted for mounting relative to the toolholder. The at least one insert includes at least one chip removal channel.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of the present invention are well understood by reading the following detailed description in conjunction with the drawings in which like numerals indicate similar elements and in which:

FIGS. 1A-1E are side cross-sectional, top perspective, bottom perspective, bottom plan, and top plan views of a cutting tool according to an embodiment of the present invention;

FIGS. 2A-2F are top, rear perspective, bottom rear perspective, top plan, side cross-sectional, bottom plan, and side plan views of a cutting insert according to an embodiment of the present invention;

FIGS. 3A-3F are top, rear perspective, bottom rear perspective, top plan, side cross-sectional, bottom plan, and side plan views of a cutting insert according to another embodiment of the present invention;

FIGS. 4A-4B are, respectively, a side cross-sectional and a broken perspective view of a portion of a cutting tool according to an embodiment of the present invention;

FIG. 5 is a side cross-sectional view of a cutting tool according to an embodiment of the present invention;

FIGS. 6A-6B are top and side views showing relative positions of inserts for use in a cutting tool according to an embodiment of the present invention

FIGS. 7A-7C are top views of inserts according to embodiments of the present invention;

FIG. 8 is a perspective view of a guide plate according to an embodiment of the present invention;

FIG. 9 is a perspective view of a cutting tool including a guide plate according to an embodiment of the present invention;

FIG. 10A is a top plan view of a cutting tool showing hidden portions of the tool by broken lines, FIG. 10B is a top plan view of the cutting tool of FIG. 10A; and

FIG. 10C is a top plan view of a toolholder for the cutting tool of FIG. 10A, and FIG. 10D is a bottom plan view of the cutting tool of FIG. 10A showing hidden portions of the tool by broken lines.

DETAILED DESCRIPTION

An embodiment of a tool 21 for dressing electrode tips is shown in FIGS. 1A-1E. The present invention is not limited to tools for dressing electrode tips. However, for purposes of discussion the present invention will generally be described in connection with a tool for dressing electrode tips.

As seen in FIG. 1A, the tool 21 includes a toolholder 23 having an opening 25 extending through the toolholder from a top 27 of the toolholder to a bottom 29 of the toolholder along a central axis C of the toolholder. A plurality of insert mounting pockets are disposed around the opening 25 for mounting replaceable cutting inserts. The plurality of insert mounting pockets include a center pocket 31, a top pocket 33, and a bottom pocket 35.

If desired, depending upon the application, fewer or more insert mounting pockets and inserts therefor may be provided. Some types of tools, such as turning, boring, drilling, or milling tools, may have only one insert mounting pocket for mounting a single insert, while other versions of such tools may have dozens or hundreds of insert mounting pockets.

The tool 21 also includes a center insert 41 disposed in the center pocket 31, a top chamfer 43 insert disposed in the top pocket 33, and a bottom chamfer insert 45 disposed in the bottom pocket 35. When a top electrode tip and a bottom electrode tip (shown in phantom in FIGS. 6A-6B) are disposed in a dressing position relative to a top and a bottom of the opening 25 in the toolholder and the tool 21 is rotated, the center insert 41 and the top chamfer insert 43 dress the top electrode tip, and the center insert 41 and the bottom chamfer insert 45 dress the bottom electrode tip.

As seen in FIGS. 2A-2F and 3A-3F, the inserts 41, 43, and 45 may have a plurality of cutting edge portions. It is desirable that the top chamfer insert 43 and the bottom chamfer insert 45 be identical and the illustrations of the top chamfer insert in FIGS. 3A-3F and the corresponding description shall be understood to apply to the bottom chamfer insert, as well, except where otherwise noted. For the inserts 41, 43, and 45, designations of “left” and “right” are substantially arbitrary and for purposes of discussion as the inserts will ordinarily be formed to be indexable such that left can become right and vice versa.

Cutting edge portions are defined for purposes of the present application as portions of a cutting edge that are intended to be exposed to and contact a workpiece such as an electrode tip. Exposed, in the sense used here, means that the cutting edge portion is in a position where it is adapted to contact a workpiece, instead of merely being visible but not adapted to contact a workpiece in any meaningful fashion. A cutting edge portion may comprise all or, more typically, part of a cutting edge.

It is desirable that at least one of the center insert 41, the top chamfer insert 43, and the bottom chamfer insert 45 is indexable to permit at least one of two or more cutting edge portions to be exposed. Ordinarily, all of the inserts will be indexable to multiple positions to permit multiple cutting edge portions to be exposed. In this way, it is not necessary to dispose of a cutting insert every time a cutting edge portion is worn or broken. If the cutting edge portion is worn or broken, the insert can simply be indexed to expose a different cutting edge portion.

For example, as seen in FIG. 1A, in the tool 21, at any given time, two cutting edge portions 41 ¹ and 41 ² of the center insert 41 are exposed, one portion 41 ¹ being closer to a top of the opening 25 and one portion 41 ² being closer to the bottom of the opening, and two cutting edge portions 41 ³ and 41 ⁴ are not exposed. As seen in FIGS. 1D and 1E, corners of the center insert by the exposed cutting edge portions can be disposed at or near the central axis C of the toolholder 23.

By turning the center insert 41 through 180°, the two cutting edge portions 41 ¹ and 41 ² that were exposed are moved to a position where they are not exposed, and the two cutting edge portions 41 ³ and 41 ⁴ that were not exposed are moved to a position where they are exposed. Thus, the center insert 41 is indexable to two different positions to expose four cutting edge portions 41 ¹, 41 ², 41 ³, and 41 ⁴. In the tool 21, at least one, ordinarily two, of the cutting edge portions 41 ¹, 41 ², 41 ³, and 41 ⁴ of the center insert is disposed at or near a center axis C of the opening.

Also, in the tool 21, at any given time, one cutting edge portion of the top chamfer insert 43 and one cutting edge portion of the bottom chamfer insert 45 is exposed. Corners of the top chamfer insert 43 and the bottom chamfer insert 45 by the exposed cutting edge portions can be disposed at approximately the same radius from the central axis C of the toolholder 23, albeit usually at different radial positions, and at approximately the same axial positions as ends of the exposed cutting edge portions of the center insert 41. In this way, when the toolholder rotates relative to electrode tips, the exposed cutting edge portions of the top and bottom inserts and the center insert do not fail to contact any portion of the electrode tips that one desires to dress. It may, in fact, be desirable for there to be some overlap of the rotational paths of the cutting edge portions of the various inserts when the toolholder rotates 23 to ensure that each electrode tip is entirely dressed.

The top chamfer insert 43 and the bottom chamfer insert 45 may each be indexable to four different positions to expose four different cutting edge portions, such as the cutting edge portions 43 ¹, 43 ², 43 ³, and 43 ⁴ for the top chamfer insert. In the tool 21, the top chamfer insert 43 and the bottom chamfer insert 45 can be identical and, in two of the index positions for the top chamfer insert and the bottom chamfer insert, the top chamfer insert and the bottom chamfer insert are seated in the top pocket 31 and the bottom pocket 45, respectively, while, in the other two index positions, the top chamfer insert and the bottom chamfer insert are seated in the bottom pocket and the top pocket respectively, i.e., the top insert becomes the bottom insert and vice versa. The number of index positions to which a particular insert is indexable and the number of cutting edge portions of an insert that are adapted to be exposed will, of course, depend upon the insert and the toolholder.

With reference to FIGS. 2A-2F, the center insert 41 may include what shall be denominated for purposes of discussion a top surface 41 t, a bottom surface 41 b, a right surface 41 r, a left surface 41 l, a front surface 41 x, and a rear surface 41 y. As seen in FIGS. 4A-4B, in the tool 21, the center pocket 31 includes a bottom supporting surface 31 b and a left side supporting surface 31 l (FIG. 1C-1D) and a right side supporting surfaces 31 r. Supporting surface portions of the center insert 41 are supported against the bottom surface 31 b and the two side (or left and right) supporting surfaces 31 l and 31 r. More specifically, in the illustrated embodiment, when the center insert 41 is oriented so that the cutting edge portions 41 ¹ and 41 ² are exposed, a supporting surface portion of the bottom surface 41 b abuts the bottom surface 31 b, a supporting surface portion of the rear surface 41 y abuts the left surface 31 l (FIGS. 1C-1D), and a supporting surface portion of the left surface 41 l abuts the right supporting surface 31 r. When the center insert is oriented so that the cutting edge portions 41 ³ and 41 ⁴ are exposed, a supporting surface portion of the top (now bottom) surface 41 t will abut the bottom surface 31 b, a supporting surface portion of the rear surface 41 y will abut the left surface 31 l, and a supporting surface portion of the right surface 41 r will abut the right supporting surface 31 r.

As seen in FIGS. 3A-3F, the top chamfer insert 43 may also have a top surface 43 t, bottom surface 43 b, right surface 43 r, left surface 43 l, front surface 43 x, and rear surface 43 y. As seen in FIGS. 1A-1E. the top pocket 33 and the bottom pocket 35 may also have respective bottom supporting surfaces 33 b and 35 b, left supporting surfaces 33 l and 35 l, and, if provided right supporting surfaces. Ordinarily, a right supporting surface, if provided, would be perpendicular to the left supporting surface like the right supporting surfaces 35 r and 33 r shown in phantom in FIGS. 1E and 1C, respectively. The right supporting surfaces may be omitted as shown in FIGS. 1B-1E, as may be desirable, for example, to facilitate machining of the toolholder 23, and other surfaces discussed here may also be omitted.

Omission of the right supporting surfaces for the pockets 33 and 35 in the tool 21 should not have substantially deleterious, if any, effect on the dressing of the electrode tips. For example, if the chamfer inserts 43 and 45 are properly seated against the left supporting surfaces 33 l and 35 l and if the chamfer inserts have straight cutting edges, they will form the same chamfer shape on the electrode tips regardless whether their positions relative to the toolholder 23 differ slightly along a direction of the left supporting surfaces 33 l and 35 l. Stated differently, it may be permissible for the chamfer inserts 43 and 45 to shift somewhat along a direction of the left supporting surfaces 33 l and 35 l.

When the top chamfer insert 43 is mounted in the top pocket 33 so that the cutting edge portion 43 l is exposed as seen in FIG. 1E, the bottom surface 43 b of the top chamfer insert abuts the bottom supporting surface 33 b of the top pocket as seen in FIG. 1A, the rear surface 43 y of the top chamfer insert abuts the left supporting surface 33 l of the top pocket as seen in FIG. 1E, and, if a right supporting surface 33 r of the top pocket is provided, the left surface 43 l of the top chamfer insert abuts the right supporting surface of the top pocket. When the top chamfer insert 43 is indexed in the top pocket 33 to expose the cutting edge portion 43 ³, the top surface 43 t of the top chamfer insert will abut the bottom supporting surface 33 b of the top pocket, the rear surface 43 y of the top chamfer insert will abut the left supporting surface 33 l of the top pocket, and the right surface 43 r of the top chamfer insert will abut the right supporting surface 33 r, if provided, of the top pocket.

The top chamfer insert 43 may still further be indexed to expose either of the cutting edge portions 43 ² and 43 ⁴. However, in this case, the top chamfer insert 43 can be indexed to expose the cutting edge portions 43 ² and 43 ⁴ by mounting the top chamfer insert in the bottom pocket 35. For example, to expose the cutting edge portion 43 ², the top (now bottom) surface 43 t of the top chamfer insert will abut the bottom supporting surface 35 b of the bottom pocket, the rear surface 43 y of the top chamfer insert will abut the left supporting surface 35 l of the bottom pocket, and the left surface 43 l of the top chamfer insert will abut the right supporting surface 35 r (if provided) of the bottom pocket. If the top chamfer insert 43 is indexed in the bottom pocket 35 to expose the cutting edge portion 43 ⁴, the bottom surface 43 b of the top chamfer insert will abut the bottom supporting surface 35 b of the bottom pocket, the rear surface 43 y of the top chamfer insert will abut the left supporting surface 35 l of the bottom pocket, and the right surface 43 r of the top chamfer insert will abut the right supporting surface 35 r (if provided) of the bottom pocket.

In the embodiment described here, the bottom supporting surface 31 b of the center pocket 31 may be perpendicular to the central axis C of the opening 25 of the toolholder 23 and the left and right supporting surfaces 31 l and 31 r may be parallel to the central axis of the opening of the toolholder, i.e., perpendicular to the bottom supporting surface 31 b. The bottom surfaces 33 b and 35 b of the top and bottom pockets may be disposed at non-zero angles relative to the central axis C, ordinarily corresponding to, or bearing a relationship to, the angle at which it is desired to form a chamfer on the electrodes. The left and right supporting surfaces 33 l and 35 l and 33 r and 35 r are ordinarily perpendicular to the bottom supporting surfaces 33 b and 35 b of the top and bottom pocket 33 and 35, respectively. The bottom supporting surface 31 b of the center pocket 31, the bottom supporting surface 33 b of the top pocket 33, and the bottom supporting surface 35 b of the bottom pocket 35 ordinarily lie in planes disposed at non-zero angles relative to one another.

The opening 25 permits chips from the electrode tips being dressed to fall away from the electrodes. It also permits the center insert 41 to perform a dressing operation on both a top and a bottom electrode tip at the same time. The center insert 41, the top chamfer insert 43, and the bottom chamfer insert 45 can all be secured in the various pockets 31, 33, and 35 of the toolholder 23 by means such as securing screws 47 (FIGS. 4A-4B) that extend through through holes 41 h (FIGS. 1C and 1D), 43 h (FIG. 1E), and 45 h (FIGS. 1A, 1C, and 1D) in the inserts into internally threaded holes in the bottom surfaces of the pockets of the toolholder such as the threaded hole 31 h seen in FIGS. 4A-4B.

It is desirable that the internally threaded holes, e.g., hole 31 h, be provided in relatively thick portions of the toolholder 23 so that a sufficient number and length of the threads on the securing screws 47 will engage with internal threads in the holes to provide good support for the inserts 41, 43, and 45 relative to the pockets 31, 33, and 35. In many conventional inserts, a central axis of a through hole for receiving a securing screw is at a geometrical center of the insert and the insert is at least rotationally symmetrical and/or has reflection symmetry about the axis. If desired, the holes 41 h, 43 h, and 45 h can each have an axis disposed along a line of rotational or reflective symmetry.

It has been found to be desirable, for the inserts 41, 43, and 45 in the embodiment of the tool shown in FIGS. 1A-1E and 4A-4B, to offset the axis of the holes 41 h, 43 h, and 45 h relative to a line of reflective symmetry, such as the line of reflective symmetry A in FIGS. 2C-2E and 3C-3D. As seen with reference to FIGS. 1A-1E and 4A-4B, it may be desirable to form the pockets 31, 33, and 35 in a ring-shaped portion of the toolholder 23 surrounding the opening 25. The ring-shaped portion of the toolholder 23, in cross-section, is substantially triangular or in the form of a truncated triangle, with a corner of the triangle facing the central axis C of the opening 25. The ring-shaped portion may generally correspond to or bear a relationship to part of the desired shape of an electrode tip to be dressed, e.g., the chamfered portion surrounding a radiused tip. Bottom surfaces 33 b and 35 b of the top and bottom pockets 33 and 35 may lie in planes defining the same or substantially the same angle with the central axis as the sides of the triangle.

The thickness of the ring-shaped portion of the toolholder 23 decreases toward the central axis C of the opening. It may, therefore, be desirable to offset the axis of the holes 41 h, 43 h, and 45 h relative to the line of reflective symmetry because, when the inserts 41, 43, and 45 are mounted relative to the pockets 31, 33, and 35, the holes 41 h, 43 h, and 45 h can align with holes in the toolholder 23 e.g., hole 31 h (FIGS. 4A-4B), formed in portions of the toolholder that are thicker, i.e., further from the tip of the triangle. This may permit more threads of the securing screws 47 to engage with threads in the holes in the toolholder than if the holes 41 h, 43 h, and 45 h were located along a line of reflective symmetry.

It has also been found to be desirable to form the holes 41 h, 43 h, and 45 h as elongated or plural holes, or what shall be referred to here as a hole arrangement, so that, when the inserts 41, 43, and 45 are indexed, an axis of a securing screw can pass through the inserts along what shall be referred to here as different axes X and Y of the hole arrangements. As seen in, for example, FIGS. 2C-2E and 3C-3E for the center insert 41 and the top chamfer insert 43, respectively, the hole arrangements 410 and 430, respectively, can be formed as, for example, substantially “figure 8” shapes so that the securing screw 47 (FIGS. 4A-4B) can pass through the holes along either of two axes X and Y. As noted above, the description of the top chamfer insert 43 can be the same as the description of the bottom chamfer insert 45 and a separate description of the bottom chamfer insert is therefore not provided.

The hole arrangements 410 and 430 may be in a variety of suitable shapes. For example, the hole arrangements may simply be elongated, i.e., oval, so that the axis of a screw can pass through a hole at a plurality of different hole axes. Also, instead of having a single hole, the hole arrangements may be made up of a plurality of discrete holes as seen in FIG. 7A so that the axis of the screw can pass through the insert along a plurality of different hole axes. The hole arrangements can be formed, as well, in shapes such as “tri-star” shapes as seen in FIG. 7B and “X” shapes as seen in FIG. 7C, which may be appropriate depending upon factors such as the number of ways that the insert can be indexed. For example, an insert with a tri-star shaped hole arrangement might be indexed three ways, six ways, or some other multiple of three, an insert with an X-shaped hole arrangement might be indexed four ways, eight ways, or some other multiple of four. For example, if the insert of FIG. 7C were octagonal instead of square, it may be possible to index the insert to sixteen (or more) different positions.

Whatever the shape of the hole arrangements 410 and 430 is when viewed in a direction of the axis or axes through the hole arrangements, the hole arrangements may be formed to be narrower toward a center of the inserts 41, 43, and 45 along the axes through the hole arrangements, i.e., viewing the insert in cross-section, so that the hole arrangements taper from wider openings at the top and bottom of the insert to relatively narrower “waists” at the center. FIG. 5 shows an illustrative insert 100 in cross-section. The securing screws 47 can have a shape whereby the screws gradually taper up in diameter at some point close to the head of the screw.

The hole arrangements 1000 in the inserts 100 and the holes 200 h in the pocket 200 can be positioned relative to one another when the insert is disposed in the pockets so that, as a screw 47 is tightened in the threaded hole, the tapered portion of the screw—an insert abutment surface 49 of the screw 47—will tend to contact a tapered surface—a screw abutment surface 51—of a hole arrangement and force the rear and left or right surfaces of the insert against the left and right surfaces of the pocket as the top or bottom surfaces of the insert are driven against the bottom supporting surface of the pocket.

As seen in FIGS. 2A-2C, 2E, 3A-3C, and 3E, the rear surfaces 41 y and 43 y of the inserts 41 and 43 (and 45) can be divided into plural insert supporting surface portions by recesses 41 z and 43 z. The recesses provide at least two benefits. One benefit is that a smaller portion of the rear surface of an insert, i.e., the portion not including the recess, needs to meet precise dimensional tolerances desired in cutting inserts.

Another benefit is that the provision of the recess facilitates precisely and stably mounting the inserts relative to their pockets by ensuring desirable three-point contact between an insert and its pocket. In the case, for example, of a center insert 41, three point contact is ordinarily achieved through contact between a point on the bottom 41 b (or top 41 t) of the insert and the bottom 31 b of the pocket 31, a point on the rear surface 41 y and the left surface 31 l of the pocket, and a point on the right surface 41 r (or left surface 41 l) of the insert and the right surface 31 r of the pocket. In the case of a top insert 43 (or bottom insert 45) to be mounted in a top or bottom pocket 33 or 35 having no right surface, three point contact can be achieved by contact between two points on the rear surface 43 y on opposite sides of the recess 43 z and the left surface 33 l or 35 l of the pocket, and contact between the bottom 43 b (or top 43 t) of the insert and the bottom 33 b or 35 b of the pocket.

With reference generally to FIGS. 2A-2F and 3A-3F, the inserts 41, 43, and 45 are ordinarily symmetrical about at least one axis A and the insert hole arrangements 410 and 430 are ordinarily configured such that at least two of the at least two different axes X and Y are offset from the at least one axis of symmetry. More particularly, the inserts 41, 43, and 45 can be symmetrical about a plane A parallel to an axis of the insert hole arrangement 410 and 430. The inserts 41, 43, and 45 can also, or alternatively, be symmetrical about a plane B perpendicular to an axis of the insert hole arrangement 410 and 430. Other inserts can have rotational symmetry about a central axis of a hole arrangement.

The top and bottom chamfer inserts 43 and 45 can be, but are not necessarily, identical and interchangeable. The top and bottom chamfer inserts 43 and 45 can include cutting edge portions, e.g., portions 43 ¹, 43 ², 43 ³, and 43 ⁴ for top chamfer insert 43, that have straight portions S (FIGS. 3A-3B) to chamfer an electrode tip so that at least a portion of the electrode tip has a constant cone angle. The center insert 41 is ordinarily, but not necessarily, different than the top and bottom chamfer inserts 43 and 45. The cutting edge portions 41 ¹, 41 ², 41 ³, and 41 ⁴ of the center insert 41 may, for example include a radiused portion R (FIGS. 2A-2B) so that a tip of the electrode tip will have a radius surrounded by a straight chamfered portion formed by any of the straight cutting edge portions of the top and bottom chamfer inserts. Of course, the top and bottom chamfer inserts 43 and 45 and the center insert 41 may all be identical or may all be different. The top and bottom chamfer insert 43 and 45 and the center insert 41 may include plural straight and/or radiused portions depending upon the shape to which it is desired to dress the electrode tip. The cutting edge portions of any insert can be shaped according to the shape desired for the workpiece.

In the tool 21, the center insert 41 and the top (and bottom) chamfer inserts 43 (and 45) are rotated such that the front surfaces 41 x and 43 x are rake surfaces, and portions 41 c and 43 c of the top and bottom surfaces 41 t and 41 b, and 43 t and 43 b are clearance surfaces. More particularly, in a given insert, the clearance surfaces are disposed between the insert hole arrangement and the cutting edges portions of the inserts at the intersection the top surface and the front surface and at the intersection of the bottom surface and the front surface. A length of the top intersection between the top surfaces 41 t and 43 t and the front surface 41 x and 43 x and a length of the bottom intersection between the bottom surfaces 41 b and 43 b and the front surfaces 41 x and 43 x can be longer than a distance between the clearance surfaces on the top and bottom surfaces of the insert.

It is presently believed to be desirable that the clearance surfaces 41 c and 43 c define an angle of greater than or equal to 7° to a plane perpendicular to an axis of a respective insert hole arrangement or a plane passing through forwardmost points of the front surface 41 x and 43 x, here denominated the plane of the front or rake surface. More particularly, it is presently believed to be desirable that the clearance surfaces 41 c and 43 c define an angle of approximately 15° to a plane perpendicular to an axis of a respective insert hole arrangement. The clearance angle provided on a given insert may, of course, differ as appropriate for the particular application. The clearance surfaces may each define an acute angle with the rake surface, i.e., the front surfaces 41 x and 43 x. The front surfaces 41 x and 43 x can be substantially straight as shown in the Figures, however, a more complex geometry can be provided if desired, such as a chipformer geometry to assist in chip formation and removal.

Behind the cutting edge portions and below the clearance surfaces 41 c and 43 c, the inserts 41 and 43 (and 45) may also be provided on their top and bottom surfaces (41 t, 43 t, 41 b, 43 b) with raised abutment portions 41 a and 43 a that can abut against the bottom surfaces of the pockets, assist in chip removal, and provide additional strength to the insert proximate the insert hole arrangements 410 and 430. The raised portions 41 a and 43 a may serve other purposes, as well, such as assisting in positioning the inserts 41, 43, and 45 in the pockets 31, 33, and 35 by mating with corresponding depressions (not shown) in the pockets, if provided.

FIGS. 6A and 6B show the relative positions of the center insert 41, the top insert 43, and the bottom insert 45 with the toolholder 23 removed. The electrode tips 300 (shown in phantom) include a radiused portion 303 formed by radiused cutting edge portions of the center insert 41 and straight chamfered portions 305 formed by straight cutting edge portions of the top and bottom chamfer inserts 43 and 45. Of course, if inserts having shapes other than the radiused and straight cutting edge portions of the inserts 41, 43, and 45 are provided, other electrode tip shapes can be provided as desired.

As seen in FIG. 6A, the cutting portions of the inserts define a “Y” shape around the central axis C. The “Y” shape can assist in balancing forces on the electrode tips compared to cutting tools that have inserts arranged substantially along a straight line, such as in U.S. Pat. No. 5,401,127. By improving the balance of forces on the electrode tips, it can be less necessary to provide support for the electrode tips and greater flexibility can be provided in terms of the forms of electrode tips that can be dressed.

Regardless how well balanced the forces on the electrode tips are, it is often desirable to provide support for the electrode tips. FIG. 8 shows a guide ring 400 and FIG. 9 shows the guide ring installed in a cutting tool 21 and secured by a set screw 401 that mates with threads on the toolholder 23 (not shown) and contacts an abutment surface 403 on the guide ring to hold the guide ring in place relative to the toolholder. If desired, the threads on the guide ring can be omitted and the screw 401 can engage with threads on the toolholder and hold the guide ring. The guide ring 400 can be used to facilitate guiding an electrode tip to a desired position along or relative to the central axis C. For example, if axes of the electrode tips extend along or are parallel to but offset radially from the central axis C, a vertical surface 405 of the guide plate can provide support for the electrode tips. If an axis of the electrode tips is to be disposed at an angle to the central axis C, then an angled surface 407 of the guide plate 400 can provide support for the electrode tips. The guide ring can be provided with bearings (not shown) on its angled and/or vertical surfaces if desired.

Another embodiment of the cutting tool 621 is shown in FIGS. 10A-10D. The cutting tool 621 includes a toolholder 623 and at least one insert 641, 643, 645 adapted for mounting relative to the toolholder. The insert 641, 643, 645 includes at least one chip removal channel 661, 663, 665 intersecting a clearance surface 700 situated adjacent a cutting edge portion. When the insert is one of a plurality of inserts used for dressing electrode tips, the insert can be indexable to two or four positions in the manner described above. For purposes of illustration, the inserts shown in FIGS. 10A-10D are shown as being indexable to a single position (center insert 641) or to two positions (chamfer inserts 643 and 645), however, it will be understood that the inserts can be indexable to two, four, or some other desired number of positions as in other embodiments described herein.

The toolholder 623 can include a central opening 625 and a plurality of inserts 641, 643, 645 can be mounted relative to the toolholder around the central opening. For each of the plurality of inserts 641, 643, 645, the chip removal channel 661, 663, 665 faces the central opening 625 of the toolholder 623. For each of the plurality of inserts 641, 643, 645, the chip removal channel 661, 663, 665 can be arranged to remove chips cut by another one of the plurality of inserts. More specifically, in the case of an electrode tip dresser as illustrated in FIGS. 10A-10D, the chip removal channel 661, 663, 665 of each insert 641, 643, 645 removes chips formed by a cutting edge of an insert 645, 641, 643, respectively, disposed behind the insert in a direction of rotation of the cutting tool. In other forms of cutting tools, of course, this may not necessarily be the case.

In the cutting tool of FIGS. 10A-10D, the inserts 641, 643, 645 each include a plurality of cutting edge portions. For the chamfer inserts 643, 645, when mounted relative to the toolholder, one of the cutting edge portions is in a cutting position. For the center insert 641, when mounted relative to the toolholder, two cutting edge portions are in cutting positions. The center insert 641 will ordinarily be mounted relative to the toolholder 623 so that its cutting edge portions are substantially perpendicular to a central axis of the toolholder.

In addition to having chip removal channels in the cutting inserts, the toolholder 623 can include at least one chip removal channel 671, 673, 675. The chip removal channel 671 of the toolholder 623 and the chip removal channels 661, 663, 665 of the insert, respectively, can connect to form a cutting tool chip removal channel 681, 683, 685. The chip removal channel 671 of the toolholder 623 and the chip removal channels 661, 663, 665 of the insert, respectively, may be rounded and have the same curvature. While this embodiment has been described in connection with a cutting tool for dressing electrode tips, it will be appreciated that the present invention has application in all fields of cutting tools, such as milling, drilling, boring, and turning, as well.

While this invention has been illustrated and described in accordance with a preferred embodiment, it is recognized that variations and changes may be made therein without departing from the invention as set forth in the claims. 

1. A cutting tool, comprising a toolholder, and at least one insert adapted for mounting relative to the toolholder, wherein the at least one insert includes at least one chip removal channel.
 2. The cutting tool as set forth in claim 1, wherein the toolholder includes a central opening and a plurality of inserts is mounted relative to the toolholder around the central opening.
 3. The cutting tool as set forth in claim 2, wherein, for each of the plurality of inserts, the chip removal channel faces the central opening of the toolholder.
 4. The cutting tool as set forth in claim 2, wherein, for each of the plurality of inserts, the chip removal channel is arranged to remove chips cut by another one of the plurality of inserts.
 5. The cutting tool as set forth in claim 1, wherein the at least one insert includes a plurality of cutting edge portions.
 6. The cutting tool as set forth in claim 5, wherein, when the at least one insert is mounted relative to the toolholder, one of the plurality of cutting edge portions is in a cutting position.
 7. The cutting tool as set forth in claim 5, wherein, when the at least one insert is mounted relative to the toolholder, a plurality of the plurality of cutting edge portions are in cutting positions.
 8. The cutting tool as set forth in claim 5, wherein the cutting tool includes at least two inserts, at least one insert of the at least two inserts being mounted relative to the toolholder such that one of the plurality of cutting edge portions is in a cutting position and at least one primary insert of the at least two inserts being mounted relative to the toolholder such that a plurality of cutting edge portions are in cutting positions.
 9. The cutting tool as set forth in claim 8, wherein the at least one primary insert is mounted relative to the toolholder so that its cutting edge portions are substantially perpendicular to a central axis of the toolholder.
 10. The cutting tool as set forth in claim 1, wherein the toolholder includes at least one chip removal channel, the at least one chip removal channel of the toolholder and the at least one chip removal channel of the insert being connected to form a cutting tool chip removal channel.
 11. A cutting insert comprising an insert body including cutting edge portions and an insert hole arrangement for permitting the insert to be secured to a toolholder, said insert having a clearance surface, wherein the insert includes at least one chip removal channel intersecting said clearance surface. 